The Challenge with Manual and Semi-Automated Testing

Even in large-scale labs, many BET workflows still rely on manual or semi-automated processes:
- Analysts prepare standard curves, serial dilutions, and reagents by hand
- Sample transfers introduce variability and transcription errors
- Extended training is required before staff reach proficiency
These steps create bottlenecks, higher retest rates, and delays that affect product release. In regulated environments, a single invalid run can lead to reprocessing, wasted consumables, and compliance findings. They also drive out-of-specification investigations and tie up skilled staff with hours of dilution work instead of analysis, impacting both operational efficiency and job satisfaction.
The Nexus 200™ Solution: A Fully Automated Endotoxin Testing System

For over two decades, Endosafe® cartridge technology has helped quality control labs streamline bacterial endotoxin testing (BET) while meeting compendial standards. In 2014, the first fully automated robotic Endosafe Nexus brought walk-away automation to large-scale QC labs. The Nexus 200 builds on that foundation, doubling capacity, adding complex dilution capability, and integrating new data integrity tools.
The Nexus 200 automates the full endotoxin testing workflow in one enclosed, integrated platform. Analysts load samples, consumables, and cartridges; the system performs dilutions, pipetting, and analysis without further intervention. By replacing manual steps with precise, repeatable automation, this system:
- Reduces variability from analyst technique and environmental interference
- Increases throughput to 120 diluted or undiluted samples per run
- Handles complex and serial dilutions up to 1:32,768
- Supports FDA-licensed LAL and Trillium® recombinant cascade reagent (rCR) cartridges
- Strengthens data integrity with EndoScan-V™ software, permissions control, and secure audit trails
Its architecture combines:
- Hamilton Microlab® NIMBUS HD liquid handling for precise air-displacement pipetting in a compact footprint
- Endosafe® nexgen-MCS™ multi-cartridge system for on-deck cartridge handling, reading, and disposal
- Prefilled Endosafe cartridges that eliminate daily reagent prep, consolidate standards and duplicate sample/spike channels, and reduce pipetting steps, variability, and retest risk
Cartridge stability has been validated for extended automation runs, with customer SOPs and memos available to replicate studies in-house. This integration minimizes human touchpoints from load to result, allowing analysts to focus on interpretation and process control.
Webinar: How Automation Can Transform Your BET
Discover how cartridge-based technology simplifies endotoxin testing and how full automation like Nexus 200™ reduces errors and boosts efficiency.
Watch Now
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Key features of the Nexus 200
The Nexus 200 automates every step, from dilution to result reporting, so you can run high-volume tests without constant monitoring. Once the deck is loaded and samples are scanned, the system locks the enclosure and executes a repeatable cycle:
- Barcode verification: Integrated 1D and 2D scanning confirms sample identity before processing, reducing mix-ups and transcription errors
- Automated sample handling: Four independent pipetting channels accelerate processing and maintain precision across up to 120 samples in one run
- Onboard cartridge management: A gravity-fed cartridge dispenser stages cartridges for the nexgen-MCS. A gripper then loads them into the system for rapid duplicate-channel BET testing and transfers used cartridges to an automated waste chute
- Unified data management (New in ESV 6.3): Central database integration aligns Nexus 200 with nexgen-PTS™, nexgen-MCS, and plate readers. Shared general settings, user management, permissions, audit trails, and data storage reduce setup time and simplify compliance
- Proactive run monitoring (New in ESV 6.3): Email alerts instantly notify if a system-level interruption occurs, helping teams respond faster and avoid delays
- Adaptive testing for R&D (New in ESV 6.3): Duplicate Dilution Mode preserves limited-volume samples and automates secondary dilution testing when needed, reducing waste and manual intervention
These enhancements work together to save time, reduce manual steps, and keep every run audit-ready.

Complex Dilution Capability for Diverse Applications
The Nexus 200 supports a wide range of testing needs, so you can run water, in-process, final product, and R&D samples in the same automated workflow. It performs serial dilutions up to 1:32,768 with multiple diluents available for use in the run. Complex or duplicate dilutions can be handled automatically, preserving sample material and avoiding manual intervention.A Fully Enclosed, Safety-Focused Design
Operators and samples remain protected throughout every run:- Doors lock automatically at run start and remain locked until the system stops
- Locking caster wheels provide stability and mobility for the integrated cabinet
- The enclosure prevents environmental interference that could affect results

Error Prevention and Real-Time Oversight
By limiting manual steps, the Nexus 200 reduces opportunities for variability and retests. Real-time alerts keep runs audit-ready and enable overnight operation with minimal supervision. The combination of barcode scanning, automated cartridge handling, and system-level monitoring ensures data integrity from first pipette movement to result.Traditional BET keeps skilled analysts occupied with manual dilutions, curve preparation, and pipetting, work that carries a high risk of error but low value for advanced scientific expertise. The Nexus 200 minimizes these tasks, allowing analysts to focus on analysis, investigation, and proactive process control.
Standardized workflows across sites reduce training time, harmonize method settings, and lower the risk of deviations. Automation also shortens laboratory and out-of-specification investigations, improving efficiency and throughput without compromising compliance.
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EndoScan-V™ (ESV) Software Integration: Secure, Connected, and Compliant
EndoScan-V powers Nexus 200’s data integrity and connectivity so you can manage results confidently across your lab network.

- Data security: Backup and restore features protect critical test data
- LIMS integration: Send results directly to your lab information management system
- Audit readiness: Searchable audit trails, permissions, and digital signatures maintain full traceability and authenticity
- Global Data Standards: Meets 21 CFR Part 11 and global GMP data integrity requirements
With the Cortex™ add-on, you can monitor process control across instruments and sites in real time. ESV extends this with unified database management across Nexus 200, nexgen-PTS, and nexgen-MCS, shared user controls, and proactive email alerts for system-level events.
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Regulatory Compliance and End-to-End Support
The Nexus 200 is validated to meet global compendial and regulatory expectations so you can operate with confidence across sites and regions.
- FDA-licensed kinetic chromogenic method (LAL cartridge) since 2006, fully compliant with USP, EP, and JP
- Supports sustainability with either 95% less LAL usage per test or the use of non-animal-derived Trillium recombinant cascade reagent (rCR) cartridges
- Designed for GMP QC labs in pharma, biotech, and medical device manufacturing
To keep systems running smoothly and in compliance, a dedicated Field Service Team provides preventive maintenance, repairs, and annual calibration. Validation services are available remotely, by sending samples to a Charles River lab, or on-site during extended training at installation. This ensures automation is fully operational and audit-ready from day one.
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Product Codes
Product Code Endosafe® Nexus™ 200 Robotic System MR750020K Next generation Nexus™ Platform Endosafe® nexgen-MCS™ 3 cartridge dispensers 6 20-position racks Endoscan-V™ software Cabinet -
Product Specifications
Feature Endosafe® Nexus™ 200 Sample capacity per automation session Maximum of 120 samples, diluted or undiluted Dilution ratios Serial dilutions up to 1:32,768 Number of pipette heads 4 (increases speed of sample handling) Number of pipette tips Over 700 total tips (480-300μL and 288-1000μL) Sample rack 6 x 20 sample tube racks Bar Code 1D and 2D barcode options Operating system compatibility Windows 10 and 11 Controller External PC Application EndoScan-V™ version 6.2 and above Hardware Configuration Closed unit with integrated cabinet, waste chute Data Integrity features - Validated software with searchable audit trails
- PC controls power to all hardware
- Limited human interaction to eliminate variability
- Fully flexible user management
- Includes digital signature
Safety - Completely enclosed
- Doors locked to start automation and will not unlock unless robot is parked
- Locking caster wheels on cabinet
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Testimonials
As pharmaceutical manufacturing becomes more efficient, the demand for reliable, compliant, and high-throughput automated bacterial endotoxin solutions increases. Since the launch of Endosafe Nexus in 2014, these demands have inspired our Research and Product Development team to reimagine robotic endotoxin testing with the Endosafe Nexus 200. We are proud of this advancement of our testing portfolio.”
Birgit Girshick, Corporate Executive Vice President & Chief Operating Officer, Charles River
Investing in advanced manufacturing is more than just increasing efficiency, it reflects our company's commitment to being at the forefront of technology in a rapidly evolving environment. Automation allows us to produce our products with the greatest precision, consistency, and safety."
Niall Power, Senior Site Director, Charleston

See Nexus 200 Automation in Action
View the step-by-step demonstration video of the Nexus 200 so you can see exactly how it sets up, runs a fully automated assay, and delivers results in EndoScan-V software. No guesswork, just a clear view of automation in your lab.
Watch the Demo
Frequently Asked Questions (FAQs) About the Endosafe Nexus 200 Automated Endotoxin Testing System:
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Does the Nexus 200 come with software?
Yes, the Nexus 200 is powered by Endosafe EndoScan-V for LIMS integration and improved traceability, security, and data management. Charles River Cortex software, our endotoxin analysis software for investigative evaluation and process monitoring can be added to track and trend your endotoxin data in real-time.
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Is the integrated cabinet included?
Yes, the integrated cabinet is always included with the system and is not optional. The Nexus 200 system cannot be removed from the cabinet as it is designed to ensure stability of the system, integration of the waste chute, easy installation and the flexibility needed to maintain the system from all sides.
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What is the benefit of using the Endosafe Nexus 200 automated endotoxin testing system?
The robotic nature of the reagent handling, pipetting, and analysis employed by the Endosafe Nexus 200 means that human interaction is not necessary, therefore reduces variability in technical and transcription errors. Traditional endotoxin test methods require a laboratory technician to perform additional steps such as creating a standard curve, dilutions, rehydrating reagents, and even visual analysis of results. Additionally, automating your endotoxin testing allows you to remain complaint with data integrity standards by ensuring data are attributable, legible, contemporaneous, original, and accurate. Lab automation greatly reduces the chance of human-caused errors in the analysis, eliminates data integrity concerns over results interpretation, and maintains a high throughput environment in the laboratory by reducing additional work.
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What type of barcode symbols does the Endosafe Nexus 200 read?
Both 1D and 2D are readable so you can match your lab’s existing standards.
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Who supports all the components of the Endosafe Nexus 200 automated endotoxin testing system?
All components, in addition to preventive service, maintenance, and repairs of the Endosafe Nexus 200 automated endotoxin testing system are supported directly by Charles River.

